🎯 Process Risk Assessment: SIL Methodology & Assessment Techniques - 5-Day Course

Duration: 5 Days | 5 Hours Daily | 25 Total Hours
Level: Intermediate to Advanced

🎯 Course Overview

Intensive training on Safety Integrity Level (SIL) determination, LOPA, HAZOP, and risk assessment tools per IEC 61508/61511 and ISA 84 standards.

Target Audience: Process safety engineers, SIS engineers, instrumentation engineers, HAZOP leaders, risk assessment specialists

Prerequisites: Engineering degree, basic process safety knowledge, understanding of P&IDs

📅 DAY 1: Risk Assessment Fundamentals & HAZOP

Learning Objectives: Master risk assessment principles and conduct HAZOP studies

Modules:

1.1 Risk Assessment Principles

• Risk definitions: hazard, likelihood, consequence, ALARP

• Qualitative vs. quantitative methods

• Risk matrices and acceptance criteria

• F-N curves and risk tolerance

1.2 HAZOP Methodology

• HAZOP process and team roles

• Guidewords: No, More, Less, Reverse, As Well As, Part Of, Other Than

• P&ID review and node selection

• Deviations, causes, consequences, safeguards

• Action tracking and documentation

• Workshop: HAZOP facilitation techniques

1.3 HAZOP Practical Exercise

• Team-based HAZOP on separator/reactor system

• Complete study on provided P&ID

• Deviation scenarios and safeguard identification

• Hands-On: 2-hour HAZOP study exercise

1.4 Consequence Analysis

• Fire modeling: pool fire, jet fire, flash fire, BLEVE

• Explosion modeling: VCE, confined explosion

• Toxic dispersion: Gaussian plume, dense gas

• Impact zones and safety distances

• Demo: PHAST/ALOHA software

Deliverable: HAZOP study report

📅 DAY 2: Layer of Protection Analysis (LOPA)

Learning Objectives: Master LOPA methodology, identify IPLs, and determine SIL requirements

Modules:

2.1 LOPA Fundamentals

• LOPA methodology per CCPS guidelines

• Relationship to HAZOP and IEC 61511

• Team composition and documentation

2.2 Initiating Events

• Initiating event identification and frequency

• Generic data sources: CCPS, PDS, OREDA, API 581

• Common frequencies:

  • Pump failure: 1×10⁻¹/yr

  • Pipe rupture: 1×10⁻⁴/m-yr

  • Operator error: 1×10⁻¹ to 1×10⁻²/demand

  • Control valve failure: 1×10⁻¹/yr

• Exercise: Initiating event frequency determination

2.3 Independent Protection Layers (IPLs)

• IPL criteria: effectiveness, independence, auditability

• IPL categories with typical PFD:

  • Process design: 10x (PFD 0.1)

  • BPCS: 10x (PFD 0.1) - specific criteria

  • Critical alarms + operator: 10x (PFD 0.1)

  • SIF: SIL 1-4 (PFD 0.1 to 0.0001)

  • Relief devices: 10x-100x (PFD 0.1-0.01)

  • F&G + mitigation: 10x (PFD 0.1)

• IPL independence requirements

• Workshop: IPL identification exercise

2.4 LOPA Calculations

• Risk tolerance criteria

• MEL = Initiating Event × ∏(PFD of IPLs)

• Required RRF = Initiating Freq / Tolerable Freq

• SIL determination from required PFD

• Hands-On Lab: 10+ LOPA scenarios with calculations

2.5 Advanced LOPA

• Multiple initiating events

• Enabling events and conditional modifiers

• Common cause failures

• Demand rate effects

• Case Study: Complex LOPA scenarios

2.6 LOPA Documentation

• Worksheet structure and templates

• IPL justification

• SIL assignment documentation

• Exercise: Complete LOPA documentation

Deliverable: LOPA study with SIL requirements

📅 DAY 3: SIL Determination & Verification

Learning Objectives: Master SIL selection methods and perform detailed verification calculations

Modules:

3.1 SIL Overview

• IEC 61508, IEC 61511, ISA 84 standards

• SIL levels and PFD ranges:

  • SIL 1: 0.1 to 0.01 (RRF 10-100)

  • SIL 2: 0.01 to 0.001 (RRF 100-1,000)

  • SIL 3: 0.001 to 0.0001 (RRF 1,000-10,000)

• Low demand vs. high demand mode

3.2 SIL Selection Methods

• Risk Graph method (IEC 61511)

• Risk Matrix method

• LOPA method (Day 2)

• Quantitative Risk Assessment (QRA)

• Workshop: SIL determination using multiple methods

3.3 Reliability Engineering

• Failure rate (λ), MTTF, MTTR, PFD

• Failure modes: DD, DU, SD, SU

• Safe Failure Fraction (SFF)

• Diagnostic Coverage (DC)

• Proof test coverage (PTC)

• Common cause (β factor): 2%-10%

3.4 SIL Verification Calculations

Single channel (1oo1):

• PFDavg = (λDU × TI) / 2

Redundant architectures:

• 1oo2: PFDavg ≈ β×(λDU×TI)/2 + (λDU×TI)²/3

• 2oo3: PFDavg ≈ 3×β×(λDU×TI)²/2 + (λDU×TI)³

• 2oo2, 1oo3, 2oo4, MooN configurations

Typical failure rates:

• Pressure transmitter: λDU = 0.5-1.0×10⁻⁶/hr

• Temperature transmitter: λDU = 0.3-0.8×10⁻⁶/hr

• Logic solver: λDU = 5-20×10⁻⁶/hr

• Shutdown valve: λDU = 1-5×10⁻⁶/hr

Hands-On Lab: SIL verification for multiple architectures (2 hours)

3.5 Reliability Data Sources

• OREDA, PDS, SERH, IEEE 500

• Manufacturer data vs. generic data

• Environmental adjustment factors

• Exercise: Data source selection

3.6 Proof Testing

• Proof test intervals and coverage

• Effect of PTC on PFDavg

• Partial stroke testing

• Interval optimization

• Workshop: Test interval determination

3.7 SIL Verification Software

• exSILentia, SILcalc, SINTEF tools

• Reliability block diagrams

• Fault tree analysis for SIS

• Hands-On: Software exercises

Deliverable: SIL verification calculations

📅 DAY 4: Advanced Risk Assessment Tools

Learning Objectives: Master FTA, ETA, Bowtie, and QRA methodologies

Modules:

4.1 Fault Tree Analysis (FTA)

• FTA methodology and symbols

• AND/OR gates and Boolean algebra

• Top event probability calculations:

  • AND: P(Top) = P(A) × P(B)

  • OR: P(Top) ≈ P(A) + P(B) (rare events)

• Minimal cut sets

• Hands-On: Develop FTA for process scenario

4.2 Event Tree Analysis (ETA)

• Initiating events and pivotal events

• Success/failure branches

• Sequence frequency calculations

• Integration with FTA

• Case Study: Fire scenario ETA

4.3 Bowtie Methodology

• Central hazard identification

• Preventive barriers (threats to hazard)

• Mitigative barriers (hazard to consequences)

• Degradation factors

• Software tools: BowTieXP

• Workshop: Develop Bowtie diagram

4.4 Quantitative Risk Assessment (QRA)

• QRA framework and methodology

• Frequency assessment techniques

• Consequence modeling integration

• Risk metrics: IRPA, PLL, FAR, F-N curves

• Risk acceptance criteria

• Case Study: Offshore/chemical plant QRA

4.5 Human Reliability Analysis (HRA)

• Human error types and probability (HEP)

• Methods: THERP, HEART, CREAM

• Performance Shaping Factors

• Typical HEP values: 1×10⁻³ to 1×10⁻¹

• Operator action credit in LOPA

• Exercise: HRA calculations

4.6 Software Tools

• PHAST: consequence modeling

• ALOHA: toxic dispersion

• Fault Tree+ / RiskSpectrum: FTA/ETA

• BowTieXP: barrier management

• exSILentia: SIL verification

• DNV Safeti: QRA

• Hands-On: Software demonstrations

Deliverable: FTA/ETA report, Bowtie diagram

📅 DAY 5: Applications & Capstone Project

Learning Objectives: Apply techniques to real scenarios and complete integrated project

Modules:

5.1 Safety Requirements Specification (SRS)

• SRS content per IEC 61511:

  • SIF description and safe state

  • SIL assignment with justification

  • Response time and proof test interval

  • Functional and integrity requirements

  • Bypass and reset requirements

• Templates and best practices

• Workshop: Develop SRS for 2 SIFs

5.2 Application-Specific Risk Assessment

• HIPPS: SIL 3 requirements, <2 sec response

• Burner Management Systems: SIL 2-3, NFPA 85

• ESD Systems: Multiple inputs, depressurization

• Tank Overfill: SIL 2, time-to-overflow

• Case Studies: Each application

5.3 Documentation & Lifecycle Integration

• Study report structure

• HAZOP, LOPA, SIL reports

• Action tracking and closeout

• Risk studies in project phases:

  • Conceptual: HAZID

  • FEED: Preliminary HAZOP, LOPA

  • Detailed: Final HAZOP, SIL verification, SRS

  • Operations: Revalidation (5 years)

5.4 Quality & Peer Review

• Competency requirements

• Common pitfalls to avoid:

  • Missing safeguards

  • Incorrect IPL credits

  • Over-crediting operators

  • Ignoring common cause

• Independent verification

• Functional Safety Assessment (FSA)

• Workshop: Peer review exercise

5.5 Capstone Project

Integrated Risk Assessment:

Teams develop complete study for assigned unit (distillation, reactor, separator, tank farm):

Deliverables:

1. HAZOP: 2-3 nodes with deviations, safeguards, rankings

2. LOPA: 5+ scenarios with IPLs and SIL determination

3. SIL Verification: 3 SIFs with architecture and calculations

4. Additional Analysis: FTA, ETA, or Bowtie

5. SRS: Complete specifications for 2 SIFs

6. Report: Executive summary, methodology, findings, recommendations

Presentation: 25 minutes + Q&A

5.6 Best Practices & Lessons Learned

• Case studies of failures

• Common errors and solutions

• Industry incidents analysis

• Continuous improvement

5.7 Professional Development

• Certifications: TÜV FSE, ISA CAP-S, CFSP, HAZOP Leader

• Advanced topics: Cybersecurity (IEC 62443), AI in risk assessment

• Resources and communities

• Course evaluation

Deliverable: Complete risk assessment project

🛠️ Standards & Software

Standards: IEC 61508, 61511 | ISA 84 | CCPS LOPA | API RP 754, 520, 521 | NORSOK Z-013 | ISO 31000

Software (Hands-On): exSILentia | PHAST | ALOHA | BowTieXP | Fault Tree+ | SILcalc

Databases: OREDA | PDS | SERH | IEEE 500 | OGP Risk Data

Excel Templates: LOPA worksheets | SIL calculators | Risk matrices | Reliability data

📚 Course Materials

• Technical manual (450+ pages)

• Standards excerpts (IEC 61511, ISA 84)

• 25+ case studies

• Excel calculation toolbox

• Software user guides

• LOPA/HAZOP templates

• SRS template library

• Reliability data compilation

• Certificate (40 PDH / 4.0 CEU)

• 90-day technical support

🎓 Learning Outcomes

✅ Facilitate HAZOP studies per IEC 61511
✅ Conduct LOPA and identify IPLs
✅ Determine SIL using multiple methods
✅ Perform SIL verification for all architectures
✅ Apply reliability data (OREDA, PDS)
✅ Develop Safety Requirements Specifications
✅ Conduct FTA, ETA, and Bowtie analysis
✅ Perform QRA with consequence modeling
✅ Use industry software (exSILentia, PHAST)
✅ Integrate risk assessment in project lifecycle

📞 Enrollment

Delivery: In-Person | Virtual Live | On-Site Corporate
Locations: Houston | Aberdeen | Singapore | Dubai | Calgary
Class Size: Maximum 18 participants
Discounts: 15% group (3+), 10% early bird (45+ days)

🔍 Keywords

SIL determination | Safety Integrity Level | LOPA training | HAZOP course | IEC 61511 | ISA 84 | Process risk assessment | SIL verification | Functional safety | Risk assessment tools | FTA ETA | Bowtie methodology | QRA | exSILentia training | PHAST software | SRS | OREDA PDS | IPL analysis | Process safety | Oil gas safety

⭐ Why This Course?

✔️ 60% hands-on calculations & software
✔️ Training on exSILentia, PHAST, BowTieXP
✔️ Real reliability data (OREDA, PDS)
✔️ Excel toolbox included
✔️ Expert instructors (20+ years)
✔️ Global recognition (Shell, BP, Chevron)
✔️ 40 PDH / 4.0 CEU